Intercooler System

ABSTRACT

The present invention relates to an apparatus and a system that may be utilized to maximize and utilize greater air flow through an intercooler apparatus. The present invention utilizes unique coil configurations and designs to help promote better air flow through an intercooler apparatus. The present invention utilizes unique profiled passage separators to improve air flow through the passages of the intercooler. Additionally, the present invention utilizes profiled passage separators that improve and significantly cool temperatures of the air flow in much smaller packaging because of the unique passage separators and air flow design of the intercooler.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of and is a continuation of U.S.patent application Ser. No. 13/473,765, filed May 17, 2012, which claimsthe benefit of priority of U.S. Provisional Patent Application No.61/487,645, filed May 18, 2011, which are incorporated in their entiretyby reference into this application.

FIELD OF THE INVENTION

The present invention relates generally to the field of vehicleperformance parts. More specifically, the present invention relates toan apparatus and system to maximize airflow through a vehicleintercooler.

BACKGROUND OF THE INVENTION

On any given vehicle, there are thousands of functioning and necessaryparts. These essential parts are usually interlinked with other parts ofan overall system to make a vehicle run efficiently.

For many car enthusiasts, modifying a factory vehicle with upgradedaftermarket parts is rewarding and satisfying in a multiplicity ofdifferent ways. Many individuals decide to modify their vehicles foraesthetic purposes. However, many individuals modify or alter theirvehicles to elicit better performance from their vehicle or to upgradefrom more restrictive parts that come with their vehicle from thefactory to less restrictive parts with better usability and/orperformance.

There are some common aftermarket modifications that most vehicleenthusiasts, such as car owners, motorcycle owners, boats, and othergasoline/diesel powered vehicle owners choose to employ. A few of thesecommon aftermarket modifications are replacement of a vehicle exhaustsystem and replacement of headers (tubes that run from the engine anddirect unwanted heat and exhaust away from the engine). Additionally,many individuals will recalibrate a vehicle's computer which regulatesengine speed and other functions, to elicit higher performance andtolerances. Another common type of vehicle modification is thereplacement of the stock air filter with an aftermarket air filter.However, a problem with modifications is that they are limited in theirability to produce the desired increase in power and performance.

When an individual user decides on increasing power and performance,thereby increasing the performance of the vehicle outside of what theoriginal manufacturer had anticipated when they produced the vehicle, itis necessary to modify the vehicle with parts that were not intended.For example, one of the more widely utilized forms of increasingperformance on any vehicle is to utilize forced induction by eitherturbocharging the vehicle or supercharging the vehicle.

A turbocharger is a type of gas compressor used to increase the pressureof air entering the engine of a vehicle. The turbocharger is usuallymade of at least a turbine, and often times by multiple turbines that isdriven by the engine's exhaust gases. In contrast, a supercharger ispowered by mechanical drive. This allows a turbocharger to compoundvarious cycles to achieve greater power or higher efficiency or both.

On the other hand, a supercharger is an air compressor that forces moreair into the engine of a vehicle. The greater mass flow-rate providesmore oxygen to support combustion than would be available in anon-supercharged engine. This supercharging capacity allows for morefuel to be burned by the engine and increases the power output of theengine. Power for the unit can come mechanically by a belt, gear, shaft,or chain connected to the engine's crankshaft.

However, one problem that exists with a forced induction system is heat.Turbo chargers utilize an engine's exhaust gases after the liquid gashas been heated and burned by the engine. Similarly, supercharges forcemore air into the engine of the vehicle and cause more fuel to be burnedby the engine, thereby creating more exhaust gases, and in turn, moreheat.

In an effort to solve this heating problem, manufacturers of forcedinduction systems have created a cooling system for these vehicleshaving forced induction systems (such as turbochargers andsuperchargers). Intercoolers have attempted to solve some of theseheating problems.

An intercooler is an air-to-air or air-to-liquid heat exchange deviceutilized in combination with turbocharged or supercharged systems onvehicle engines to improve their volumetric efficiency by increasingintake air charge density through nearly constant pressure cooling,which removes the heat of compression that occurs in any gas when itspressure is raised or its unit mass per unit volume is increased. Adecrease in intake air charge temperature sustains use of a more denseintake charge into the engine, as a result of supercharging. Thelowering of the intake charge air temperature also eliminates the dangerof pre-detonation of the fuel air charge prior to timed spark ignition,thus preserving the benefits of more fuel/air burn per engine cycle andincreasing the output of the engine. Intercoolers increase theefficiency of the induction system by reducing induction air heatcreated by the turbocharger and promoting more thorough combustion. Theyalso eliminate the need for using the wasteful method of lowering intakecharge temperature by the injection of excess fuel into the cylinders'air induction chambers, to cool the intake air charge, prior to itsflowing into the cylinders. This wasteful practice nearly eliminated thegain in engine efficiency from supercharging, but was necessitated bythe greater need to prevent the engine damage that pre-detonation engineknocking caused.

However, a problem with prior art intercoolers is that air flow and airto liquid flow must be maximized in order to maximize cooling andtherefore, performance of a forced induction system. Thus, to maximizethe benefits of utilizing air flow, a large intercooler must beutilized. However, prior art intercoolers have limitations on the amountof airflow and the efficiency of air flow through the intercoolerbecause of their design.

A need therefore exists for an improved apparatus and system forproducing an intercooler that may maximize and greatly increase flowthrough the intercooler. Additionally, a need therefore exists for animproved apparatus and design for an intercooler to maximize flow andincrease performance of an entirety of a forced induction system.

SUMMARY OF THE INVENTION

The present invention relates to an apparatus and a system that may beutilized to maximize and utilize greater air flow through an intercoolerapparatus. The present invention utilizes unique coil configurations anddesigns to help promote better air flow through an intercoolerapparatus. The present invention utilizes unique profiled passageseparators to improve air flow through the passages of the intercooler.Additionally, the present invention utilizes profiled passage separatorsthat improve and significantly cool temperatures of the air flow in muchsmaller packaging because of the unique passage separators and air flowdesign of the intercooler.

To this end, in an exemplary embodiment of the present invention, anapparatus for cooling air to the engine of a vehicle is provided.

To this end in an exemplary embodiment of the present invention, a heatexchange apparatus for improving fluid flow, the apparatus comprising: ahot fluid inlet end and a cooled fluid discharge end; an internalportion having a cooling fluid path contained within the internalportion of the heat exchange apparatus; a plurality of cooling fluidpassageways in the cooling fluid path portion; and a plurality ofprofiled passageway separators.

In an exemplary embodiment, wherein the fluid path is utilized to cool agaseous fluid.

In an exemplary embodiment, wherein the fluid path is utilized to cool aliquid fluid.

In an exemplary embodiment, wherein the plurality of profiledpassageways are capped by a convex surface to funnel fluid moreefficiently through the passageways.

In an exemplary embodiment, wherein the convex surface is connected tothe passageway on the hot fluid inlet end of the heat exchangeapparatus.

In an exemplary embodiment, wherein the convex surface is connected tothe passageway on the cooled fluid discharge end of the heat exchangeapparatus and the hot fluid inlet end of the heat exchange apparatus.

In an exemplary embodiment, wherein the apparatus applies basic fluidmechanics to the entry and exit of the cooling fluid passageways toimprove air flow through the heat exchanger device.

In an exemplary embodiment, wherein the apparatus utilizes uniqueshaping of the passageways of the apparatus to greatly improve air flowthrough the apparatus.

In an exemplary embodiment, wherein the unique shaping comprises awave-like coil configuration.

In an exemplary embodiment, wherein each cooling fluid passageway isseparated from another cooling fluid passageway by a material.

In an exemplary embodiment, wherein the material is a metal.

In another exemplary embodiment, wherein the internal portion isadjacent to a plurality of end tanks.

In an exemplary embodiment, the apparatus can be uniquely small ascompared with the prior art intercooler designs because currentintercooler technology is based on size for an application, so thehigher the heat rejection requirement the larger the intercooler. Withthe current state of art in intercoolers, most other heat exchangingdevices do not pay attention to the fluid flow entering and exiting thecore of the exchanger. The unique design of the present invention allowsfor greater fluid flow through the intercooler to more adequately coolwithout the need for a larger sized intercooler apparatus.

In an exemplary embodiment, the apparatus has a channel whereby fluidflow is channeled there through and cooling of the fluid flow isaffected.

In an exemplary embodiment, the apparatus applies basic fluid mechanicsto the entry and exit of the hot side passages of the heat exchangers toimprove air flow through the heat exchangers and/or intercoolers.

In an exemplary embodiment, the apparatus utilizes unique shaping of thepassageways of the intercooler to greatly improve air flow through theapparatus.

In an exemplary embodiment, the apparatus correctly and uniquely shapesthe entry into and out of the passages of the intercooler apparatus togreatly increase air flow through the heat exchange apparatus.

In an exemplary embodiment, a heat exchange apparatus is providedwhereby the same profiles can be applied to the hot side and cold sideof the intercooler. The concept is to provide a shaped entry profileinto each internal air passage by forming the bars of material thatseparate each passage.

In an exemplary embodiment, the heat exchange apparatus has a pluralityof fluid flow passages that allow for cooling of the fluid flow therethrough.

In an exemplary embodiment, the heat exchange apparatus has a pluralityof fluid flow passages that allow for cooling of the fluid flow therethrough and further wherein the passageway has at least a hot sideportion and a cold side portion.

In an exemplary embodiment, the heat exchange apparatus has a pluralityof fluid flow passages that allow for cooling of the fluid flow therethrough and further wherein the passageway has at least a hot sideportion and a cold side portion whereby each passageway is separatedfrom another passageway by a material, the material preferably being ametal and/or substantially rigid material.

In an exemplary embodiment, the heat exchange apparatus has a pluralityof fluid flow passages that allow for cooling of the fluid flow therethrough and further wherein the passageway has at least a hot sideportion and a cold side portion whereby each passageway is separatedfrom another passageway by a material, the material preferably being ametal or substantially rigid material and further wherein the passagewaymaterial has a distal portion and a proximal portion each ending with auniquely configured abutment.

In an exemplary embodiment, the heat exchange apparatus has plurality ofprofiled passage separators.

To this end, in an exemplary embodiment of the present invention, theheat exchange apparatus has plurality of profiled passage separators,the profiled passage separators connected to both a hot side portion anda cold side portion of the heat exchange apparatus. It should beunderstood that cold side profile passage separators may be eliminatedyet still attain the desired effects of increasing fluid flow throughthe heat exchange apparatus and to cool fluid flow through theapparatus.

Various objects, features, aspects and advantages of the presentinvention will become more apparent from the following detaileddescription of preferred embodiments of the invention, along with theaccompanying drawings in which like numerals represent like components.

Thus, specific embodiments and applications of an intercooler systemhave been disclosed. It should be apparent, however, to those skilled inthe art that many more modifications besides those already described arepossible without departing from the inventive concepts herein. Theinventive subject matter, therefore, is not to be restricted except inthe spirit of the appended claims. The terms “comprises” and“comprising” should be interpreted as referring to elements, components,or steps in a non-exclusive manner, indicating that the referencedelements, components, or steps may be present, or utilized, or combinedwith other elements, components, or steps that are not expresslyreferenced.

Additional features and advantages of the present invention aredescribed herein, and will be apparent from the detailed description ofthe presently preferred embodiments and from the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side perspective view of the apparatus exterior in anexemplary embodiment of the present invention;

FIG. 2 is a side perspective view of the apparatus interior in anexemplary embodiment of the present invention;

FIG. 3 is a front cross-sectional view of the apparatus in an exemplaryembodiment of the present invention;

FIG. 4 is a close-up view of the heat exchange apparatus illustratingthe profiled passage separators in an exemplary embodiment of thepresent invention; and

FIG. 5 is another close-up view of the heat exchange apparatusillustrating the profiled passage separators in an exemplary embodimentof the present invention.

DETAILED DESCRIPTION

The present invention relates to an apparatus and a system that may beutilized to maximize and utilize greater air flow through an intercoolerapparatus. The present invention utilizes unique coil configurations anddesigns to help promote better air flow through an intercoolerapparatus. The present invention utilizes unique profiled passageseparators to improve air flow through the passages of the intercooler.Additionally, the present invention utilizes profiled passage separatorsthat improve and significantly cool temperatures of the air flow in muchsmaller packaging because of the unique passage separators and air flowdesign of the intercooler.

FIG. 1 shows a heat exchange apparatus 100 in accordance with anembodiment of the present invention. In an exemplary embodiment of thepresent invention, an apparatus for cooling air to the engine of avehicle is provided. Air flow 140, as hot air, enters the heat exchangeapparatus through the hot fluid inlet end 110 of the end tanks 125. Thespecially designed shape of the end tanks 125 increases volumetricefficiency. Heat build-up is reduced, which keeps the intake chargecool. Smooth internal features minimize air turbulence and maximize airflow. By correctly shaping the entry into and out of the heat exchangeapparatus 100, air flow is greatly increased. A more efficientintercooler lets the turbo and the motor run far cooler and produce morepower.

In an exemplary embodiment, the apparatus 100 can be uniquely small ascompared with the prior art intercooler designs because currentintercooler technology is based on size for an application, so thehigher the heat rejection requirement the larger the intercooler. Withthe current state of art in intercoolers, most other heat exchangingdevices do not pay attention to the fluid flow entering and exiting thecore of the exchanger. The unique design of the present apparatus allowsfor greater fluid flow through the intercooler to more adequately coolwithout the need for a larger sized intercooler apparatus.

FIG. 2 shows the internal portion 150 of the heat exchange apparatus 100in accordance with an embodiment of the present invention. The coilconfiguration 120 may be seen in both the side and front view of theapparatus 100. Profiled passage separators 105 on the front and side ofthe apparatus 100 provide a shaped entry profile into each internal airpassageway 135 (also referred to herein as a “cooling fluid path”) byforming bars of material, preferably being a metal or substantiallyrigid material, that separate each passage. Each passageway is separatedfrom another passageway by a profiled passage separator 105. Thisstructure serves to reduce the dimensions of the vena contracta in theflow path. Vena contracta is the point in a fluid stream where thediameter of the stream is the least, and fluid velocity is at itsmaximum.

FIG. 3 is a front cross-sectional view of the internal portion 150 in anexemplary embodiment of the present invention. The heat exchangeapparatus 100 has a plurality of fluid flow passages that allow forcooling of the fluid flow there through and further wherein thepassageway 135 has at least a hot fluid side inlet end 110 and a cooledfluid discharged end 115. Air flow 140 is seen entering the end tanks125 of the heat exchange apparatus 100 at the hot fluid inlet end 110,passing through the cooling fluid passageways 135 by shaped entry due tothe convex surfaces, and exiting at the cooled fluid discharge end 115.In an exemplary embodiment, a heat exchange apparatus is providedwhereby the same profiles can be applied to the hot side and cold sideof the intercooler. The concept is to provide a shaped entry profileinto each internal air passageway 135 by forming the bars of material,profiled passage separator 105, that separate each passage. The heatexchange apparatus 100 has a plurality of fluid flow passageway 135 thatallow for cooling of the fluid flow there through. The passageways havea distal portion and a proximal portion each ending with a uniquelyconfigured abutment, preferably in the form of a convex surface 130.

FIG. 4 is a close-up view of the heat exchange apparatus 100illustrating the profiled passage separators 105 in an internal portion150. In an exemplary embodiment, the apparatus has a passageway 135whereby fluid flow is channeled there through and cooling of the fluidflow is affected. The apparatus 100 utilizes convex shaping of thepassageways of the intercooler to greatly improve air flow through theapparatus 100. Air flow 140 enters the hot fluid inlet end 110 by beingfunneled past the convex surface 130 of the profiled passage separators105.

FIG. 5 is another close-up view of the heat exchange apparatus 100illustrating the profiled passage separators 105 in an internal portion150. The cooling fluid path 135, beginning at the hot fluid inlet end,ends at the cooled fluid discharge end 115. The apparatus applies basicfluid mechanics to the entry and exit of the hot side passages of theheat exchangers to improve air flow through the heat exchangers. Theapparatus correctly and uniquely shapes the entry into and out of thepassageway 135 of the apparatus 100 to greatly increase air flow.

Thus, specific embodiments and applications of an intercooler systemhave been disclosed. It should be apparent, however, to those skilled inthe art that many more modifications besides those already described arepossible without departing from the inventive concepts herein. Theinventive subject matter, therefore, is not to be restricted except inthe spirit of the appended claims. The terms “comprises” and“comprising” should be interpreted as referring to elements, components,or steps in a non-exclusive manner, indicating that the referencedelements, components, or steps may be present, or utilized, or combinedwith other elements, components, or steps that are not expresslyreferenced.

What is claimed is:
 1. A heat exchange apparatus for improving fluidflow, the apparatus comprising: a hot fluid inlet end and a cooled fluiddischarge end; an internal portion having a cooling fluid path containedwithin the internal portion of the heat exchange apparatus; a pluralityof cooling fluid passageways in the cooling fluid path portion; and aplurality of profiled passageway separators.
 2. The apparatus of claim1, wherein the fluid path is utilized to cool a gaseous fluid.
 3. Theapparatus of claim 1, wherein the fluid path is utilized to cool aliquid fluid.
 4. The apparatus of claim 1, wherein the plurality ofprofiled passageways are capped by a convex surface to funnel fluid moreefficiently through the passageways.
 5. The apparatus of claim 4,wherein the convex surface is connected to the passageway on the hotfluid inlet end of the heat exchange apparatus.
 6. The apparatus ofclaim 4, wherein the convex surface is connected to the passageway onthe cooled fluid discharge end of the heat exchange apparatus and thehot fluid inlet end of the heat exchange apparatus.
 7. The apparatus ofclaim 1, wherein the apparatus applies basic fluid mechanics to theentry and exit of the cooling fluid passageways to improve air flowthrough the heat exchanger device.
 8. The apparatus of claim 1, whereinthe apparatus utilizes unique shaping of the passageways of theapparatus to greatly improve air flow through the apparatus.
 9. Theapparatus of claim 1, wherein the unique shaping comprises a wave-likecoil configuration.
 10. The apparatus of claim 1, wherein each coolingfluid passageway is separated from another cooling fluid passageway by amaterial.
 11. The apparatus of claim 10, wherein the material is ametal.
 12. The apparatus of claim 1, wherein the internal portion isadjacent to a plurality of end tanks.